Most of the temperature and stress fields simulations in laser cladding were based on flat surface, while actually cladding
may occur on any curved surface. The difference between cladding on flat surface and curved surface is that the latter
will result in uneven distribution of laser power. Experiments of laser cladding have been done on different material
gears under various technical conditions, and crackles have been observed by SEM. Some factors that affect laser power
actually, such as laser shielding, the incident angle of laser and curved surface of gear are all considered. Based the
analysis of the shape of layer after cladding and the phase transformaion during cladding, temperature and stress fields of
gear surface laser cladding have been simulated by ANSYS in this article. The results indicate that appropriate material
matching and base preheating can decrease the likelihood of crackles, even eliminate it.
Laser cladding monitoring is one of the cladding layer quality controlling methods. At present, cladding monitoring
usually monitor the temperature or the shape of melting pool. The height deviation between melted and unmelted point is
also considered. In this paper, optical signal of plasma which is one of the characteristic signal of plasma has been
detected by phototube in cladding. The relationship between blue-violet light intensity and laser power scan velocity has
been discussed, and the relevance between quality of layer and intensity has been analysed as well. The results indicate
that while laser power growed the intensity increased just at a low rate, and the intensity decreased as scan velocity
increased when the power is lower than a definite value. But when the power is greater than this value the intensity will
rise as velocity increase. The quality of layer is improved greatly when the intensity value rang from 1.7 μW/cm2 to
2.5μW/cm2 with a slight fluctuation.
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